If you need help with using the resin/bodyfiller/fiberglass ask a parent or someone responsible to help. It can be a very dangerous medium to work with.
What you will need:
X-Acto Knife and a pack or two of fresh #11 Blades (USE WITH CAUTION, YOU CAN LOSE A FINGER VERY FAST!)
Pepakura - HERE (a program for unfolding 3D models to be printed out on paper and re-assembled)
Bandit Thug File - HERE
Superglue (USE WITH CAUTION!)
Various bits of plastic, colored foam sheets and styrene for the mouth piece and other details
2 Flashlight Ends with lenses
Paints and brushes (I used acrylics)
Fiberglass with proper mask if you want to go full safety (NOT the same mask as resin)
Resin with proper mask for full safety (NOT the same mask as fiberglass)
Dremel or other rotory tool with proper cutting attachments
Hot Glue and Glue Gun
Here's a screenshot of the game showing the helmet we will be making HERE
Step 1: Step 1
Once you get it to the correct size for your head then you assemble the helmet using superglue as it will make this process go a lot faster. On the red lines you fold a mountain "^" and on the blue lines you fold a valley "V". cut on dotted lines.
Step 2: Step 2
At this stage it's sturdy for being nothing but cardstock but it will still be flimsy on the planes.
Step 3: Step 3
Apply with a brush to get into all cracks and crevasses but be sure the brushes you use are either resin safe or ones you can throw away.
After the entire helmet has been covered and cured you should have something that is a lot more sturdy but still flimsy to a point and a shiny look to it..
Step 4: Step 4
When doing the fiberglass step it helps to use strips of fiberglass in the same manner as paper mache. First apply some resin to the inside of the helmet where you are wanting to apply the strip of glass. Then lay the glass down in the area. Now use another brush and dip it into the resin. Start dabbing the glass from the straight up position if possible making sure to coax the glass into corners as best as possible.
The glass will slide around in the resin. This is normal and a pain. Just try to work through this as carefully as possible and all should be ok.
This step does not give the helmet it's "final look", it's just a reinforcement step. I would be sure to put glass on the ENTIRE inside planes and cracks and you may want a second layer of glass once the first is cured for added strength. I've only got one layer on mine because it's only used for conventions but If I could go back I would have added a second layer so I could go without the worry of punching a possible hole in a weak spot.
When finished you should have something similar to the photos
Step 5: Step 5
Also go ahead and using the Flashlight end piece mark out where the eye holes will be.
After about 30 minutes or so (depending on how much there is to cut off and sand down) you should end up with something like the photo.
Step 6: Step 6
Step 7: Step 7
Once it's dry, apply a second layer of filler and repeat the process above. Do this for a total of 3 - 4 layers of filler.
After it's all sanded how you want or are happy with install the flashlight parts into the eyelets and whatever pieces you chose for the mouth vent (rims only not lenses!) with some hotglue around them. Don't worry about the hotglue looking messy as long as you keep it around them.
Step 8: Step 8
Once you've gone through a few hours or days of sanding it's finally time to paint this puppy. Take the helmet to a well ventilated area and spray on some flat black primer. This will serve as the base coat of the helmet. Be sure to put about 2 - 3 coats on it to ensure a nice even color.
Alternate paint step. You can also paint it with a red primer (2 - 3 coats). Then silver (2 coats) and finally flat black (2 - 3 coats). When painting like this you can then take some 60 grit sandpaper and scrape some corners or other spots on the helmet and it will give an effect of paint scratched off of a metal helmet. the red primer would serve as the deepest part of a scrape where the metal is rusting.
Once you've got your base color(s) down just take your acrylic paints/brushes and paint on the details. Be sure to use a silver paint and paint the hot glue gobs. It will give the effect of being welded into place.
Once painted it should look something like this